Booklet form paperboard package for media disks

ABSTRACT

A package for housing one or more items such as optical media discs is constructed from alternating layers of material such as paper and paperboard. The various layers are adhered together to form the package. The package has a book like form. The layers of paperboard have internal spaces for holding discs. The layers of paper are folded and the folds make up at least part of a binding. Projections into the internal spaces may be used to limit unintended movement of the items within the internal spaces.

REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of International ApplicationNo. PCT/US09/034114, filed Feb. 13, 2009, which claims priority fromU.S. Provisional Application No. 61/028,767, filed Feb. 14, 2008. Thisapplication also claims priority to U.S. Provisional Application No.61/233,612, filed Aug. 13, 2009. All three of the applications listedabove are incorporated by reference herein in their respectiveentireties.

BACKGROUND OF THE INVENTION

The present invention relates generally to a closable storage packagefor a recording medium and, more particularly, to a package comprising apaper board book-like assembly for storing one or more discs.

Various types of planar discs are in use at the present time to recordand store information which is to be retrieved by various means, such asby optical or magnetic means. Typical of such discs are compact discs inwhich information is digitally recorded by use of a laser beam and thenread optically by a laser beam. Such discs are used to record audioinformation such as musical renditions, video information such as visualimages and digital information for use as read only and other memoriesfor use in various applications, such as computer applications. In mostinstances, at the present time, such discs are sold with informationalready recorded thereon. In other applications, such discs are sold inblank form and are used by the customer to record information thereon.In the latter case, for example, optical discs are sold for use ascomputer storage media and are used in hard disc storage systems. Asused herein, the terms media disc, compact disc, CD or disc are intendedto encompass all such discs, whatever their size, for all known orproposed uses.

Compact discs containing laser recorded information are typicallypackaged in injection molded plastic enclosures designed to hold one ormore CDs for protecting the discs during storage and shipment.Enclosures commonly used at the present time, such as the well known“jewel box,” comprise a three piece assembly consisting of a base orbottom element, an insert or tray in the base/bottom element forpositioning and supporting the disc in the base/bottom element, e.g., bya center projection (commonly referred to as a “rosette”) which engagesthe periphery of the aperture in the center of the disc, and a lid orcover which is hinged to the base/bottom element and is closed thereonafter the disc is mounted therein on the tray. Other enclosures maysupport a disc or discs within booklet-like structure made partially orcompletely of paper or paperboard.

There remains a need for a simple, sturdy, environmentally friendly,attractive, and inexpensive to manufacture CD package that adequatelyprotects the disc yet provides easy access thereto.

SUMMARY OF THE INVENTION

It is an object of the present disclosure to provide a package forholding discs that is easy to manufacture from paper board or similarsuitable environmentally friendly and/or recyclable material andadhesive such that the finished package is sturdy and attractive.

The present disclosure is directed to a package for housing one or morediscs in a booklet-like package including one or more pages comprisingmultiple plies some of whose material is partially cut away to provide aholding space for at least one disc. Variations of the illustrativeembodiments are also within the contemplation of the present disclosure,including variations in the size, shape, material, and number of thepages, and the size, shape, number and location of the cutaway areas forholding discs.

It should be appreciated that the present invention can be implementedand utilized in numerous ways, including without limitation as aprocess, an apparatus, a system, a device, and a method for applicationsand from other suitable materials now known and later developed. Theseand other unique features of the system disclosed herein will becomemore readily apparent from the following description and theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill in the art to which the disclosedsystem appertains will more readily understand how to make and use thesame, reference may be had to the following drawings.

FIG. 1 shows an isometric view, prior to assembly, of a blank forforming part of a media package.

FIG. 2 shows an isometric view of the blank of FIG. 1, during a stage ofits folding.

FIG. 3 shows an isometric view of additional parts as of FIG. 2, beingassembled into a media package.

FIGS. 4A and 4B show top views of the media package.

FIG. 5 shows an isometric view of the media package of FIG. 3, holdingoptical media.

FIG. 6 shows an isometric view of the media package of FIG. 5, in a moreopen configuration.

FIG. 7 shows an isometric view of another variation on the mediapackage.

FIG. 8 shows an isometric view of another variation on the mediapackage.

FIG. 9A shows an isometric view of another embodiment of a part of amedia package prior to assembly.

FIG. 9B shows a detail view of FIG. 9A.

FIG. 10 shows an isometric view prior to assembly of another blank forforming part of a media package.

FIG. 11 shows an isometric view after assembly of the part formed fromthe blank of FIG. 10.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present disclosure is for a book-like package for optical media orother items. The advantages, and other features of the package disclosedherein, will become more readily apparent to those having ordinary skillin the art from the following detailed description of certain exemplaryembodiments taken in conjunction with the drawings which set forthrepresentative embodiments of the present invention and wherein likereference numerals identify similar structural elements wheneverpossible.

All relative descriptions herein such as left, right, up, down, topside,underside and the like are with reference to the Figures, and not meantin a limiting sense. The illustrated embodiments can be understood asproviding exemplary features of varying detail of certain embodiments,and therefore, unless otherwise specified, features, components,modules, elements, and/or aspects of the illustrations can be otherwisecombined, interconnected, sequenced, separated, interchanged,positioned, and/or rearranged without materially departing from thedisclosed systems or methods. Additionally, the shapes and sizes ofcomponents are also exemplary and unless otherwise specified, can bealtered without materially affecting or limiting the disclosedtechnology to holding discs exclusively.

Exemplary embodiments of the present invention are illustrated in FIGS.1-10, in which there are shown improved optical media packages made frompaper and adhesive. In brief overview, the packages are made from foldedsheets of (generally) a lighter weight sheet material (such as paper)with plies of a (generally) heavier weight sheet material (such aspaperboard) sandwiched between. Cutout areas are provided in the heavierweight (paperboard) to receive optical media.

FIG. 1 shows certain parts the package prior to assembly. A first sheetof paper 10 is folded into panels 12A and 12B along a score line 14. Acutting line 18 may be provided, which is shown in dashed line in thedrawing; this cutting line 18 may or may not be indicated by a visiblemarking. Beyond the cutting line 18 are trim panels 12C and 12D that maybe removed in later trimming operations. A central aperture 16 may beprovided in one or both panels 12A and 12B. A peripheral aperture 17 mayalso be provided in one or both panels 12A and 12B.

A second sheet 20 is folded into panels 22A and 22B along a score line24. As with the first panel, cutting line 28, central aperture 26, andperipheral aperture 27 may be provided in the second sheet 20.

Shown between first sheet 10 and second sheet 20 is third sheet 30,which in the assembled configuration may hold optical media 50. Thethird sheet 30 may for example be formed of a paperboard, such as apaperboard having a thickness of about 0.036 inches. A cut line 34,shown as approximately “U” shaped, defines a removable region 32B thatwill ultimately be removed to make room for the optical media. However,at this point of the assembly, removable region 32B is still connectedwith the rest of third sheet 30, represented by permanent region 32A. Acutting line 38 is shown on third sheet 30.

FIG. 2 shows the parts of FIG. 1 having been brought together so thatthe third sheet 30 is sandwiched between the first and second sheets,forming an assembly 100. This may be done by applying adhesive to bothsides of third sheet 30, excepting the removable region 32B, thenplacing the first sheet and second sheet on opposing surfaces of thirdsheet 30. The assembly as shown in FIG. 2 is an example of a stage inthe construction of a multi-page booklet form package for holding one ormore optical media. However, the assembly 100 as shown in FIG. 2 may beutilized as a package for a single disc, in which case central aperture26 and peripheral aperture 27 may be omitted from the second sheet.

FIG. 3 shows a step in the assembly of a multi-page booklet-like packagefor holding one or more optical media. In this case additional pages 210are provided within the package. Pages 210 each may comprise for examplea first sheet (e.g. a lighter paper sheet as previously described) and athird sheet (e.g. a heavier paperboard sheet as previously described).The pages may be adhered together as explained in FIG. 2.

FIG. 4A shows a top view of the assembly as shown in FIG. 3, beforeadhering the parts together. It can be seen that the structure includessix of the third sheet 30, separated by five of first sheet 10, allbetween a “front cover” of first sheet 10 and a “rear cover” of secondsheet 20. All of the facing surfaces of these sheets would be gluedtogether as explained in FIG. 2, which then gives the package 200 asshown in top view in FIG. 4B, where the internal pages 210 are eachshown as a unit.

After the component sheets have been glued together to form as manyconnected pages as desired, the package may be cut along cutting lines18, 28, and 38, leaving package 200 appearing as shown in FIG. 5. Theremovable regions 32B are now free to be removed from the assembly, andtheir removal leaves internal spaces to receive optical media 50 (shownfully enclosed in the package) and optical media 51 (shown partlyremoved from the package). Removal from the package is facilitated bythe peripheral apertures 17 which permit the disc edge 57 to be grasped,or by the central apertures 16 that permit the disc to be lifted byplacing a finger in the disc hub opening 56.

Besides cutting the package along cutting lines 18, 28, and 38 asdescribed, the other edges may also be trimmed or cut, excepting thejoined edge that serves as the spine (e.g., along fold 14 and itscounterparts). The removable region 32B may be recycled, or it may beused as feed stock for other uses. It may be pre-printed beforeassembly, to form promotional materials, coupons, cards, and other itemsuseful to the purchaser or the manufacturer of the package.

FIG. 5 shows the appearance of the package 200 with only the front cover(represented by panel 12A) and the rear cover (represented by panel 42B,also showing its cutting line 48) opened outward. FIG. 6 shows anotherview of the package, with the pages 210 splayed somewhat apart to show amore typical use situation.

Since the facing surfaces at any “page” in the page in the package aremade of a single continuous sheet of paper (such as facing surfaces 12Aand 12B), a continuous graphic image may be printed without anydisruptive discontinuities at the binding edge, which is merely the fold14 between the facing panels.

FIG. 7 shows another embodiment as package 300 in which front pages 301,302, 303, and 304 and back pages 317, 318, and 319 do not house opticaldiscs. Such non-disc pages may occur in any desired number and may belocated anywhere in the package, including interspersed between pagesthat house discs. Non-disc pages may include third sheet 30 if desired,but often would not include this thicker piece of material.

The package may contain one or more media discs, and each page maycontain one or more discs. FIG. 8 shows another embodiment as package400 wherein the pages each may hold two discs, for example discs 50 and51 inward toward the “binding edge and discs 60 and 61 housed toward theoutward edge of the package. In the embodiment of package 400, frontpages 401, 402, 403, and 404 and back pages 417, 418, and 419 do nothouse optical discs.

The packages may contain items other than media discs. Although in someembodiments the packages may be made from paperboard having a thicknessof about 0.036″, and paper of various thicknesses, other types andthicknesses of materials may be utilized as are known in the packagingarts. The third sheet 30 in particular may be formed of more than oneply or more than one material. For example, it may be bleached board,kraft board, dyed or otherwise colored board. The package may usemultiple style covers, including for example a hard cover (for example,as used on case bound books, coffee table books or hard back novels) orthick paperboard may be used for the cover.

The removable region 32B may be rectangular as shown in the Figures, orit may have other shapes that are suitable to accommodate an opticaldisc or other item desired to be housed in the package. For example, thebottom periphery of removable region 32B may be semi-circular to fit theperimeter of a disc, or it may have a polyhedral shape. The shape of theremovable region 32B may be simple (e.g. linear, curved) or complex. Theshape and size of central aperture 16 may be varied, or it may beomitted. Likewise the shape and size of peripheral aperture 17 may bevaried or it may be omitted. Either aperture may appear on one, both, orneither of the sheets of paper that are glued to third sheet 30.

FIG. 9A shows another embodiment of third sheet 530 (similar, forexample, to third sheet 30 shown in FIG. 1), that may fit between thefirst sheet and second sheet and hold optical media 50. The third sheet530 may for example be formed of paperboard, such as a paperboard havinga thickness of about 0.036 inches. A cut line 534, only certain segmentsof which are labeled, is shown as approximately “U” shaped and defines aremovable region 532B that will ultimately be removed to make room forthe optical media. However, at initial stages of the assembly, removableregion 532B is still connected with the rest of third sheet 530,represented by permanent region 532A. A cutting line 538 is shown onthird sheet 530.

Third sheet 530 may have one or more notches 534A that protrude inwardlytoward the region to be occupied by optical media 50. A detail view isshown in FIG. 9B. The notch or notches 532A create a slight constrictionin the path of the optical media as it is slid out of (or into) thefinished package. Such a constriction may help prevent unintendedmovement of the optical media out of the case, for example duringshipping and handling. Notch 534A may be located between the storageposition of optical media 50 (as shown in dotted line in FIG. 9B) andthe opening through which the optical media will eventually be removed,that is, at the edge approximated by cutting line 538. As shown in FIG.9B, notch 534A is positioned fairly near the storage position of opticalmedia 50, although the notch may be further away if desired. Placementof the notch near the storage position of optical media 50 holds thedisc almost completely within the package, until the customer pulls theoptical media from the package. The notch however is able to yieldslightly so that a slight tug is sufficient for pulling the opticalmedia past the notch and out of the package.

It will be realized that notch 534A creates a constriction that may alsoresist pulling removable region 532B out of the package, once assembly,gluing, and trimming is accomplished. Therefore to facilitate removal ofremovable region 532B, relief cut 534B may be made in the removableregion. The relief cut 534B may extend from the most inward point onnotch 534A, and downward to the lower end of removable region 532B.Thus, a relief portion 532C is created below notch 534A. This reliefportion 532C may be removed from third sheet 530 before assembly, forexample, during a die cutting step when cut line 534 and relief cut 534Bare made. Since removing relief portion 532C leaves a void duringfurther assembly, the relief portion may comprise a relatively a smallpart of removable region 532B, so as to provide a rather solid stack oflayers during subsequent processing steps. After assembly, when thepackage has been trimmed along cutting line 538, the central portion ofthe removable region 532B may be pulled out of the package as in theother examples. The package is thus ready to receive and hold opticalmedia 50, with notch or notches 534A holding the optical media againstinadvertently coming out of the package. However, the notches 534A aresufficiently yieldable to allow a customer to pull out the optical mediafrom the package, or replace it into the package.

One or more notches 534A may be provided on one or both sides of eachopening that receives optical media. The shapes of notches 534A andrelief portions 534C may differ from those shown in the Figures.

FIG. 10 shows another embodiment by which an additional sheet may beattached into the package prior to assembly. FIG. 10 is in certainaspects similar to FIG. 1 and therefore not all elements will bedescribed. First sheet of paper 610 may be folded into first extendingpanel 612A, panel 612B, and second extending panel 612C along scorelines 614A, 614B. A cutting line 618 may be provided.

Additional sheet 640 with flange portion 642 may be attached into thestructure by trapping the flange portion 642 between first extendingpanel 612A and second extending panel 612C as shown and fastening theseflange portion 642, first extending panel 612A, and second extendingpanel 612C together for example by gluing. FIG. 11 shows an assembledstructure with the additional sheet 640. The additional sheet 640 may bea transparent, translucent, or opaque sheet. It may be plastic, paper,or other sheet material. Instead of, or in addition to, providingadditional sheet 640 held between first extending panel 612A and secondextending panel 612C as in FIG. 10, another additional sheet (not shown)may be provided and held by its flange between panel 612B and an outwardextension page (not shown, for example extended from edge 612D. Likewiseone or more additional sheets may be attached to second sheet of paper620 by a similar method.

As noted above, the packages can be formed using a variety of materialsor substrates. For example, PRINTKOTE EAGLE®, which is composed of atleast 10% post consumer recycled material, can be used. Moreover, apolymeric substrate such as calendered POLYLITH® GC-3 can be used.POLYLITH® substrate is manufactured by Nanya Plastics of Taiwan and isdistributed in the U.S. by Granwell Products, Inc. POLYLITH® substrateis primarily formed using polypropylene resin and minerals comprisinginert calcium carbonate and titanium dioxide and the resulting substrateis strengthened by calendaring.

While the invention has been described with respect to exemplaryembodiments, those skilled in the art will readily appreciate thatvarious changes and/or modifications can be made to the inventionwithout departing from the spirit or scope of the invention.

1. A package for holding an item, comprising: a first layer of sheetmaterial, a second layer of sheet material, a third layer of sheetmaterial adhered between the first and second layers, wherein the thirdlayer has a first cutout area with a first opening to at least one edgeof the third layer, wherein the first cutout area is sized to receivethe item, and the first opening is large enough for the item to passthrough the first opening.
 2. The package of claim 1, further comprisinga second cutout area in an edge of the first or second layer, whereinthe second cutout area overlaps at least a portion of the first cutoutarea, and wherein the second cutout area is proximate to the firstopening.
 3. The package of claim 1, further comprising a third cutoutarea away from any edge of the first or second layer, wherein the thirdcutout area overlaps at least a portion of the first cutout area.
 4. Thepackage of claim 1, wherein the third layer has a thicknesssubstantially equal to or greater than the thickness of the item.
 5. Thepackage of claim 1, wherein at least one of the first and second layercomprises a first extending portion hingedly attached thereto through afold.
 6. The package of claim 1, wherein the first cutout area comprisesa yieldable constriction that resists movement of the item.
 7. A packagefor holding an item, comprising: a plurality of folded sheets eachcomprising two panels connected by a fold between the two panels, eachpanel having an inward facing surface and an outward facing surface; atleast one item-holding sheet, having a first face and a second face,wherein the first face is adhered to the outward facing surface of afirst panel of one of the plurality of folded sheets, and the secondface is adhered to the outward facing surface of a second panel ofanother of the plurality of folded sheets; wherein the item-holdingsheet has a first cutout area with a first opening to at least one edgeof the item-holding layer, wherein the first cutout area is sized toreceive the item, and the first opening is large enough for the item topass through the first opening.
 8. The package of claim 7, furthercomprising a second cutout area in an edge of at least one of the firstpanel or the second panel, wherein the second cutout area overlaps atleast a portion of the first cutout area, and wherein the second cutoutarea is proximate to the first opening.
 9. The package of claim 7,further comprising a third cutout area in at least one of the firstpanel or the second panel, away from any edge of the first or secondpanel, wherein the third cutout area overlaps at least a portion of thefirst cutout area.
 10. The package of claim 7, wherein the item-holdinglayer has a thickness substantially equal to or greater than thethickness of the item.
 11. The package of claim 7, wherein theitem-holding layer is made of one or more plies of sheet material. 12.The package of claim 7, wherein the first cutout area is sized toreceive a disc.
 13. The package of claim 7, wherein the first cutoutarea is rectangular in shape.
 14. The package of claim 7, wherein thefirst cutout area has two sides and a bottom, and the bottom is roundedin shape.
 15. The package of claim 8, wherein the second cutout areaoverlaps an edge of an item housed within the item-holding layer. 16.The package of claim 9, wherein the third cutout area overlaps a centralregion of an item housed within the item-holding layer.
 17. The packageof claim 7, wherein at least one pair of the plurality of folded sheetsis adhered together with no item-holding layer between the pair.
 18. Thepackage of claim 7, wherein the item-holding layer holds more than oneitem.
 19. The package of claim 7, the folded sheets and the item-holdingsheets form pages of a booklet, with the folds at least in part forminga binding for the booklet.
 20. The package of claim 7, wherein theinward-facing surfaces of the first and second panels form anuninterrupted surface for receiving a printed image or printedinformation.
 21. The package of claim 7, wherein the first cutout areacomprises a yieldable constriction to resist movement of the item. 22.The package of claim 21, wherein the yieldable constriction comprisesone or more notches directed inward into the first cutout area.
 23. Thepackage of claim 5, further comprising a second extending portionextending from and hingedly attached to the first extending portion; andan additional sheet comprising a flange; wherein the second extendingportion is folded upon the first extending portion, and the flange isheld between the first extending portion and the second extendingportion.
 24. The package of claim 23, wherein the additional sheetcomprises at least one of a transparent, translucent, and opaquematerial.
 25. The package of claim 7, further comprising an additionalsheet with a flange hingedly attached thereto; and an extending panelhingedly attached to the second panel of one of the plurality of sheets;wherein the extending panel is folded upon the second panel, holding theflange between the extending panel and the second panel.
 26. The packageof claim 25, wherein the additional sheet comprises at least one of atransparent, translucent, and opaque material.